Electrical Connector Terminal Positioning via Segmented Molding
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Solution Overview
Problem
Existing electrical connector molding processes result in poor true position of terminals due to stress-induced warping or deflection, leading to terminal damage and mold damage during the molding process, especially when densely arranging slender terminals.
Innovation Solution
A method involving insert molding where an insulating block is used to wrap around the terminals, followed by integrating a middle shielding sheet within an insulating body, ensuring terminals are fixed in place and preventing warping, with strategically placed recesses and through-holes for improved positioning and bonding.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Length of stationary object
If terminals are densely arranged in the insulating body to ensure thinness, then the electrical connector achieves reduced thickness, but the terminals are prone to warping or deflection due to stress, resulting in poor true position
Solution Approach 1:
The insulating body is divided into two separate modules: a lower-row terminal module and an upper-row terminal module. Each module is molded independently, allowing the terminals in each module to be properly supported and positioned without the stress and crowding problems that occur when all terminals are densely arranged in a single thin insulating body. This segmentation resolves the contradiction by enabling reduced overall thickness while maintaining manufacturing precision through modular construction.
Solution Approach 2:
The invention transitions from a single-plane dense arrangement of terminals to a three-dimensional modular structure with upper and lower rows of terminals distributed in different spatial zones. By utilizing the vertical dimension and distributing terminals across multiple modules, the design achieves thinness in the overall connector while providing adequate space within each module for proper terminal positioning and stress distribution.
2Productivity
If the entire row of upper conducting terminals is forcibly placed into the mold cavity, then the molding process can proceed, but the terminals are easily damaged by pressing or the mold is easily damaged
Solution Approach 1:
The terminal assembly is segmented into a lower-row terminal module and an upper-row terminal module that are molded separately. Each module is placed into the mold cavity independently, eliminating the need to forcibly place a dense row of slender terminals into a confined space. This segmentation allows the molding process to proceed efficiently while preventing terminal damage through gentle, separate placement of each module.
3Device complexity
If one end of a terminal that is not connected to the strip warps or deflects, then the true position of terminals deteriorates, but two adjacent terminals may approach or even contact each other
Solution Approach 1:
By dividing the terminal structure into separate upper and lower row modules, each terminal has adequate support and spacing within its module. The segmentation prevents the warping and deflection problems that occur in densely packed single-row arrangements, as each terminal has sufficient space and structural support to maintain its true position without contacting adjacent terminals.
Data Source
AI summary
An electrical connector, including an insulating body having a base and a tongue extending forward from the base. Multiple terminals are arranged on the tongue at intervals to form at least one row, each terminal having a contact portion exposed from a surface of the tongue. A middle shielding sheet is insert molded in the tongue, and located closer to a middle position of the tongue than the contact portion in a vertical direction. Two recesses are provided backward from a front edge of the middle shielding sheet. A spacer portion is formed between the two recesses of the middle shielding sheet and embedded into the tongue. In a transverse direction, the middle shielding sheet has a through-hole between at least one recess and a side edge of the middle shielding sheet. A front edge of the spacer portion extends forward beyond a front edge of the through-hole.